Water-sport garment with breathable fabric panels

ABSTRACT

A water-sport garment constructed with waterproof, breathable fabric panels and waterproof, non-breathable fabric panels. The waterproof, breathable fabric is constructed of one layer of a waterproof, breathable membrane with an inner and outer layer of synthetic knit fabric. The synthetic knit fabric is treated with a durable water repellant coating to prevent water absorption yet retain heat dissipation properties. The waterproof, breathable fabric is affixed to a conventional waterproof, non-breathable fabric used in the construction of water-sport garments. Construction of garments using panels of the waterproof, breathable fabric results in greater flexibility for the wearer, due to the waterproof, breathable fabric&#39;s improved stretchiness, as well as improved comfort for the wearer due to heat dissipation from areas of high heat generation during highly aerobic water-sports activities.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C. §119(e)to U.S. Provisional Application No. 61/369,643 filed on Jul. 30, 2010,entitled “WATER-SPORT GARMENT WITH BREATHABLE FABRIC PANELS,” which ishereby incorporated in its entirety by reference as if fully set forthherein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present disclosure are generally related to garmentssuitable for water-sports activity, and more particularly to an improvedwater-sport garment having one or more panels of waterproof, breathablefabric allowing the wearer to maintain a comfortable body temperatureand enjoy increased freedom of movement.

2. Description of the Related Art

Maintaining a comfortable body temperature while participating inwater-sport activities is a challenge. Wetsuits and other similarform-fitted garments have been developed that allow the wearer to spendmore time in cold water due to their heat retention capability. However,many water-sports only require the participant to be submerged in thewater infrequently, spending a significant amount of time with theirbody at least partially out of the water. In these situations the bodytemperature of the person wearing the form-fitted garment may rise touncomfortable levels because of physical exertion, high ambienttemperatures, direct exposure to sunlight, or some combination of thethree. It is desirable then to have a garment that insulates the bodyfrom the effects of cold water while allowing the wearer to dissipateheat, thereby maintaining a comfortable body temperature. Additionally,it is desirable to have a garment that allows for the effectivemaintenance of a comfortable body temperature without overly restrictingthe wearer's freedom of movement.

Wetsuits are a typical example of a form-fitted garment suitable forwater sports. Wetsuits are tight-fitting water-permeable suits worn bydivers, surfers, board sailors, kayakers, and swimmers to retain bodyheat. Modern wetsuits typically comprise flexible, heat-insulativematerial such as elastomer foam, one example being Neoprene foam. Fullbody wetsuits exhibit full-length arm and leg portions as well as thetrunk portion. A spring suit is one which has short sleeves andshortened leg portions, and is typically used by surfers who desiregreater freedom of movement. A bib top, similar to a tank top garment,may also be worn to increase the freedom of movement. Other examples ofsimilar types of garments include vests which cover the torso and arms,shorts which cover from the waist to the knee, hoods which cover thehead, booties which cover the feet, and gloves which cover the hands.

Wetsuits and other such form-fitted garments typically retain heat byallowing a small portion of water to enter the garment that is thenheated by the wearer's body until it reaches a comfortable level. Oneattempt at increasing the effectiveness of these types of garments isseen in U.S. Pat. No. 4,741,050, issued to O'Kane et al. In this patent,a certain type of stitching is claimed for use in wetsuits that isdurable, strong, flexible, and substantially waterproof. The overlockstitching technique in the patent reduces the influx of cold water intothe suit.

Another wetsuit designed to more effectively retain heat is seen in U.S.Pat. No. 7,395,553 issued to O'Hara. In this wetsuit, wool is affixed tothe inside of the inner layer of a wetsuit in sections which alsocreates channels without wool. The wool is more effective in retainingheat than synthetic fibers and the channels allow for water to leave thesuit. In this way the wearer may more effectively retain heat.

In an attempt to create a wetsuit suitable for a variety oftemperatures, a wetsuit with limb extensions is seen in U.S. Pat. No.6,473,904 issued to Long. This wetsuit comprises removable arm and legportions so that the wetsuit is easily modifiable for a variety ofconditions. However, the wearer's torso, chest, shoulders, and legs fromthe knee up are still covered in material that is designed to retainheat.

A uniform-stretch wetsuit material is seen in U.S. Pat. No. 7,051,375issued to Polak et al. The material in this patent comprises layers ofsynthetic rubber treated with a hydrophobic coating. This material israpid-drying and substantially impermeable to water, but does not allowfor heat to be effectively dissipated through the material.

Therefore, there is a need for a form-fitted garment for water-sportactivity that allows the wearer to maintain a comfortable bodytemperature by retaining heat where the wearer's body is submerged andby allowing the user to dissipate heat when necessary without overlyrestricting the freedom of movement.

SUMMARY OF THE INVENTION

The present disclosure provides a garment for water-sports that combinesa waterproof, breathable fabric treated with a durable water repellantcoating with conventional heat retention waterproof material.

In accordance with some embodiments, the water-sport garment provides awaterproof, breathable layered fabric comprising at least one layer ofsynthetic knit fabric and a layer of a waterproof breathable membrane,which, when affixed to a conventional heat retention waterproof materialsuch as Neoprene, provides a fabric construction suitable forapplications where both heat retention and heat dissipation are desired.

In some embodiments, two layers of synthetic knit fabric surround alayer of waterproof breathable membrane material. These two layers ofsynthetic knit fabric may be of the same or different thicknesses andmay be treated with a durable water repellant chemical to prevent waterabsorption while still retaining breathability.

Construction of a garment suitable for water sports using the disclosedwaterproof, breathable layered fabric in combination with anotherwaterproof non-breathable material also results in a garment withimproved stretchiness, allowing a wearer greater flexibility and freedomof movement as well as decreased muscle fatigue. Additionally, thedesirable heat retention properties are maintained in order to keep thewearer warm during water sports activities.

In another embodiment, a method of manufacturing a garment suitable forwater sports is presented comprising affixing one or more panels of foamrubber material having an inner and outer laminate of synthetic fabricand one or more layers of a waterproof breathable layered fabric to forma form-fitting garment. Preferably, the method further comprisestreating at least an outer layer with a durable water-repellantchemical.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the embodiments ofthe water-sport garment are described in detail below with reference tothe drawings of certain embodiments. The figures and descriptions areintended to illustrate certain aspects, advantages, and novel featuresof the garment without limiting it.

FIG. 1 is a perspective and schematic split section of the waterproof,breathable fabric used in some embodiments of the garment.

FIG. 2 is a schematic cross-section of the waterproof, breathable fabricused in some embodiments of the garment.

FIG. 3 is a schematic cross-section of the neoprene fabric used in someembodiments of the garment.

FIG. ° 4 is a schematic cross-section to illustrate the joinedcombination of the neoprene fabric and the waterproof, breathable fabricused in some embodiments of the garment.

FIG. 5 is a front perspective view of a wetsuit constructed inaccordance with one embodiment of the garment.

FIG. 6 is a rear perspective view of the wetsuit in FIG. 5.

FIGS. 7A and 7B are front and rear perspective views of a fitted vestconstructed in accordance with one embodiment of the garment.

FIGS. 8A and 8B are front and rear perspective views of a fitted vestwith shortened arm portions constructed in accordance with oneembodiment of the garment.

FIG. 9 is a side perspective view of a bootie constructed in accordancewith one embodiment of the garment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1-4 illustrate a novel waterproof, breathable fabric for use inthe construction of water-sport garments. Although this waterproof,breathable fabric is principally shown and described in conjunction witha full-body wetsuit, many of the inventive aspects can readily beadapted to other styles, such as spring suits, hoods, gloves, sleeves,booties, vests, shorts and bibs.

Certain prior art garments for water sports are constructed from aplurality of panels of foam rubber, preferably Neoprene, having at leastan inner layer of laminate of nylon for strength, some of the panelsbeing more pliable than others. The nylon laminate is formed by a weaveof long nylon strands and is characterized by a particular density, ordenier number, according to industry standards. The denier number is aunit of fineness denoting the weight (or mass) of a specified length ofnylon strand. One industry standard used is the gram weight of the nylonper 9000 meters of strand. A conventional type of nylon used in wetsuitshas a denier number of 70. The nylon strands are twisted together in acrosswise fashion, and the higher the density of the weave, the closertogether the adjacent parallel strands, resulting in more and biggerloops in each cross strands, and visa versa. Because there are more andbigger loops per strand, each strand travels a longer path through agiven length of material and, consequently, has more slack therein,allowing greater expansion when the ends are pulled. Over an area ofsuch high density nylon weave, the fabric can be stretched in twodimensions to a much greater extent than straighter weave nylon fabric.This conventional wetsuit material is very durable and has high heatinsulation capacity but is not breathable and can also be heavy andlimit the wearer's freedom of movement.

For certain applications such as sports conducted in cold water on warmdays or for participants in highly aerobic water-sports wheresubstantial amounts of heat are generated, heat dissipation from areasof high heat generation is desired to make the garment more comfortablefor the wearer. However, the garment must also retain enough heat thatthe wearer is comfortable in the cold water. Conventional materials usedin the construction of garments for water sports have high heatretention capability but can inhibit freedom of movement and retain moreheat than is comfortable for the wearer. Accordingly, the water-sportgarment with breathable fabric panels discussed herein incorporates boththe highly durable, high heat retention materials of conventionalwater-sport garments and a layered fabric composed of synthetic knitlayers sandwiching a waterproof, breathable membrane into a form-fittinggarment having improved stretchiness and heat dissipation qualities.

As illustrated in FIGS. 1 and 2, the waterproof, breathable material 10has an inner layer of synthetic knit fabric 103 and an outer layer ofsynthetic knit fabric 101. This synthetic knit comprises nylon,polyester, or any combination thereof. Between these two layers is alayer of a waterproof breathable membrane 102. The inner knit layer 103and outer knit layer 101 are treated with a durable water repellantchemical such that the resultant construction is both waterproof andbreathable. The construction of these layers results in a fabric withimproved two-dimensional stretchiness and heat dissipation capabilitythat has a lighter weight than conventional materials used in theconstruction of water sports garments. In a preferred embodiment, thewaterproof, breathable membrane comprises thermoplastic polyurethane(TPU) film, or microporous polytetrafluoroethylene (PTFE) film. Thesefilms have an elongation of about 450-550% when tested using the ASTMD882 method.

Preferably, each layer of synthetic knit fabric 101, 103 is comprised of100% polyester high gauge four-way stretch fabric having a gram weightabout 57 g/m²±5% Additionally, the inner 103 and outer 101 layers ofsynthetic knit need not be the same gram weight. To increase thethickness of the waterproof, breathable layered fabric 10, it isnecessary to increase the thickness of the synthetic knit fabric 101,103.

Prior art waterproof, breathable fabric is rigid and lacks stretchiness.The combination of a waterproof, breathable layer 102 with syntheticknit inner and outer layers 101, 103 improves the two-dimensionalstretchability of the fabric and any garment constructed of the fabric.This additional stretchiness is especially desired in the constructionof wetsuits, for example, where a uniform stretchiness prevents thegarment from binding and limiting the wearer's freedom of movement.

In a preferred embodiment, treatment of the waterproof, breathablelayered fabric 10 with a durable water-repellant chemical on both theinside 103 and the outside 101 synthetic knit layers allows the fabricto resist water absorption and allows the fabric to dry more quickly.Application of the durable water repellant chemical occurs by sprayingboth sides of the waterproof, breathable layered fabric, by chemicallywashing the fabric in the durable water repellant chemical, or bysponging the durable water repellant chemical onto the synthetic knitinner and outer layers 101, 103. Preferably, the durable water repellantchemical is applied by spraying the inner and outer synthetic knitlayers 101, 103 or by chemically washing the fabric with the durablewater repellant chemical and other chemicals (such as dye).

A conventional fabric used in the construction of water-sports garmentsis depicted in FIG. 3. This conventional fabric is typically composed ofan air encapsulated rubberized core layer 302 enclosed within two layersof a synthetic knit fabric 301, 303. These three layers together form aconstruction of a typical waterproof, non-breathable fabric 30, such asNeoprene.

As seen in FIG. 4, an area of affixation, or “seam,” 401 connects thewaterproof breathable laminate fabric 10 and the waterproofnon-breathable conventional material 30. The industry standard forjoining panels of material in the construction of water sport garmentsis a flat lock stitch or a flat lock stitch with tape. It is alsopossible to heat weld or glue the panels together edge to edge.Additionally, the panels could be glued by overlapping the sides of thefabric or using heat glue tape to hold the seams together. Other methodsof affixation not specifically discussed may also be used.

FIGS. 5 and 6, respectively, illustrate front and rear views of awetsuit 50 according to some embodiments of a water-sport garment. Thewetsuit 50 comprises a plurality of panels of foam rubber, preferablyNeoprene, and a plurality of panels of waterproof breathable laminate.The panels of waterproof breathable laminate fabric are shown as shadedareas and the unshaded areas are panels of foam rubber. The linesconnecting the panels represent seams.

Referring to FIGS. 5 and 6, the wetsuit 50 comprises a foam rubber chestportion 500 affixed to foam rubber arm portions 509 at an arm holesleeve seam 503. The chest portion 500 is also affixed to foam rubberside panels 611 at a body seam 507. The foam rubber chest portion 500 isalso affixed to a waterproof breathable laminate neck portion 501 andwaterproof breathable laminate under-arm portions 504 and 605.

The foam rubber side panels 611 in FIG. 6 are affixed to a foam rubberupper leg portion 610 and foam rubber arm portions 509 and 510. The sidepanels 611 are also affixed to a waterproof breathable laminate backportion 606. Additionally, the side panels 611 are affixed to waterproofbreathable laminate under-arm portions 504 and 605.

The zipper 603 in FIG. 6 extends from the waterproof breathable laminateback portion 606 starting at 604 to the foam rubber neck portion 602.Where the zipper 603 terminates, a section of fabric 601 is included toprotect the wearer's neck. The foam rubber neck portion 602 is affixedto a foam rubber front neck portion 502 and to foam rubber arm portions509. The front neck portion 502 additionally is affixed to a waterproofbreathable laminate neck portion 501.

The foam rubber upper leg portion 610 in FIG. 6 is affixed to foamrubber lower leg portions 609 at knee seams 508. The upper leg portion610 is also affixed to a waterproof breathable laminate inside legportion 506 and 607. Additionally, the upper leg portion 610 is affixedto waterproof breathable laminate panels behind the wearer's knees 608.

In some embodiments, the number, size, thickness, and location of thefoam rubber panels and panels of waterproof breathable laminate may bevaried to alter the heat retention, heat dissipation, and flexibilitycharacteristics of the water-sport garment. The waterproof breathablelaminate panels may be located additionally or alternatively on theshoulders, chest, legs, sides, or behind the elbows. The foam rubberpanels may also be located additionally or alternatively under the arms,behind the knees, on the inside of the legs, or between the neck andchest portions. The locations of the foam rubber panels in conjunctionwith the waterproof breathable laminate panels may be configured in sucha way as to maximize the wearer's efficiency in regulating bodytemperature. Additionally, the size of the panels may be altered toaffect the amount of heat that is dissipated or retained.

In another embodiment, the water-sport garment is a wetsuit withshortened arm and leg portions, generally referred to as a spring suit.A spring suit comprises one or more panels of foam rubber affixed to oneor more panels of waterproof breathable laminate. The foam rubber panelsmay be configured to cover one or more body parts where heat retentionis desired, such as the chest, neck, shoulders, upper arms, under arms,back, torso, upper legs, or inner legs. The waterproof breathablelaminate panels may be configured to cover one or more body parts wherefreedom of movement or heat dissipation is desired, such as the chest,neck, shoulders, upper arms, under arms, back, torso, upper legs, orinner legs. The foam rubber panels may have a thickness that ranges from0.5 mm to 5.0 mm. The thickness of the inner and outer layers of knitfabrics in the waterproof breathable fabric may have a thickness thatranges from 54 to 60 g/m².

In another embodiment, illustrated in FIGS. 7A, 7B, 8A and 8B, one ormore foam rubber panels are joined to one or more panels of waterproofbreathable laminates to form a vest. The foam rubber torso portion 700or 800 is affixed to foam rubber arm portions 701 or 801 by upper armseams 702 or 802. The torso portion 700 or 800 and arm portions 701 or801 are also affixed to waterproof breathable laminate under armportions 703 or 803 by under arm seams 704 or 804. The foam rubber torsoportion 700 or 800 and foam rubber arm portions 701 or 801 areadditionally affixed to a waterproof breathable laminate neck portion705 or 805. A zipper 706 runs from the neck portion to the torso portionon the rear of the vest. Alternatively, the vest may have shortened armportions 801 as illustrated in FIGS. 8A and 8B. Alternatively, the vestmay have no zipper as illustrated in FIG. 8B.

In other embodiments of the vest, the chest and arm panels may beconstructed out of a single panel of foam rubber. Additionally, the neckportion may comprise a panel of foam rubber. The number, size,thickness, or location of the foam rubber panels as well as the number,size, thickness, or location of the panels of waterproof breathablelaminate may vary according to the desired heat retention, heatdissipation, or flexibility characteristics of the vest.

In another embodiment, the water-sport garment is a bootie designed tobe worn on the foot, as illustrated in FIG. 9. The bootie 90 comprises awaterproof breathable laminate lower foot portion 900 affixed to awaterproof breathable laminate upper foot portion 904 at an upper footseam 905. The two panels are joined via flat lock stitching. The upperfoot portion and lower foot portion are affixed to a foam rubber panelunder foot portion 902 that extends over the rear of the wearer's footup to the elastic binding portion 903. An elastic binding portion 903 isaffixed to an open end of the combination of the upper foot portion 904and under foot portion 902.

In other embodiments of the bootie, the lower and upper foot portionsare constructed from a single piece of foam rubber. Alternatively, thelower or upper foot portions may comprise foam rubber panels in additionto the under foot portion. The number, size, thickness, or location ofthe waterproof breathable laminate panels and foam rubber panels may bevaried according to the desired heat retention, heat dissipation, orflexibility characteristics of the bootie. The upper and lower footportions may be joined at a seam with a flat lock stitch and tape, aheat weld, glue, a blind stitch, or any other suitable method forjoining panels of fabric together.

Other embodiments of a water-sport garment include a hood designed to beworn on the head, a glove designed to be worn on the hand, a bib, andshorts.

The panels of waterproof breathable laminate in some embodimentscomprise a synthetic knit fabric outer layer affixed to a waterproofbreathable membrane affixed to a synthetic knit fabric inner layer. Thesynthetic knit fabrics may be nylon, polyester, or a mixture of nylonand polyester. The outer layer and the inner layer need not comprise thesame synthetic fabric. The thickness of the synthetic knit fabric outerand inner layers is typically in the range of 54 to 60 g/m². Thethickness of the outer and inner layer need not be the same. Thewaterproof breathable membrane preferably comprises thermoplasticpolyurethane film. Additionally, the interior and exterior of the panelsof waterproof breathable laminate may be treated with a durable,water-repellant chemical.

Preferred embodiments of wetsuit include chest and torso portions usingneoprene that is 3 mm thick, and arm and leg portions that are 2 mmthick. The waterproof breathable fabric is preferably located under thearms, close to the neck, between the legs, and on the back. Thewaterproof breathable fabric is preferably 57 g/m² in those locations.

In addition, while several variations of the disclosure have been shownand described in detail, other modifications, which are within the scopeof this disclosure, will be readily apparent to those of skill in theart based upon this disclosure. It is also contemplated that variouscombination or sub-combinations of the specific features and aspects ofthe embodiments can be made and still fall within the scope of thedisclosure. It should be understood that various features and aspects ofthe disclosed embodiments can be combined with or substituted for oneanother in order to form varying modes of the disclosure. Thus, it isintended that the scope of at least some of the disclosed embodimentsherein disclosed should not be limited by the particular disclosedembodiments described above.

1. A form-fitted garment for water-sport activity, the garmentcomprising: at least one panel of foam rubber material having an innerlaminate of fabric; and at least one panel of breathable laminate havingan outer knit fabric affixed to a waterproof breathable membrane affixedto an inner knit fabric; wherein the at least one panel of foam rubbermaterial and the at least one panel of waterproof breathable laminateare affixed in an edge-to-edge relationship.
 2. The form-fitted garmentof claim 1, wherein the inner knit fabric of the at least one panel ofbreathable laminate is treated with a durable water repellant.
 3. Theform-fitted garment of claim 1, wherein the garment comprises a wetsuit.4. The form-fitted garment of claim 1, wherein the at least one panel offoam rubber material and the at least one panel of waterproof breathablelaminate are affixed in an edge-to-edge relationship with a flat lockstitch.
 5. The form-fitted garment of claim 1, wherein the waterproof,breathable membrane comprises thermoplastic polyurethane film.
 6. Awaterproof breathable wetsuit comprising: a plurality of foam rubberpanels having an inner laminate of fabric; a plurality of breathablelaminate panels having an outer knit fabric affixed to a breathablemembrane affixed to an inner knit fabric, the outer knit fabric and theinner knit fabric being treated with a durable water repellant; and theplurality of breathable laminate panels and the plurality of foam rubberpanels being affixedly joined by a seam.
 7. The wetsuit of claim 6,wherein the plurality of breathable laminate panels are situated inareas where greater heat dissipation is desired.
 8. The wetsuit of claim7, wherein the areas where greater heat dissipation is desired compriseat least one of armpits, groin, back, neck, shoulders, back of theelbow, and back of the knee.
 9. The wetsuit of claim 6, wherein theplurality of breathable laminate panels are situated in areas where lessrestriction of movement is desired.
 10. The wetsuit of claim 9, whereinthe areas where less restriction of movement is desired comprise atleast one of armpits, groin, back, neck, shoulders, back of the elbow,and back of the knee
 11. A method of manufacturing a waterproofbreathable water-sport garment, the method comprising: affixing one ormore panels of foam rubber material having an inner laminate of fabricto one or more panels of breathable laminate having an outer layer ofknit fabric affixed to a waterproof breathable membrane affixed to aninner knit fabric; and treating the inner knit fabric and the outer knitfabric of the one or more panels of breathable laminate with a durablewater repellant.
 12. The method of claim 11, further comprisingpositioning the one or more panels of breathable laminate in areas wheregreater heat dissipation is desired.
 13. The method of claim 11, furthercomprising positioning the one or more panels of breathable laminate inareas where less restriction of movement is desired.
 14. A garmentsuitable for water sports, comprising: one or more panels of foam rubbermaterial having an inner and outer laminate of synthetic fabric; and oneor more panels of a waterproof, breathable layered fabric.
 15. Thegarment of claim 1, wherein said garment comprises a wetsuit.
 16. Thegarment of claim 1, wherein said panels of a waterproof, breathablelayered fabric are thinner than said panels of foam rubber material. 17.The garment of claim 1, wherein said panels of a waterproof, breathablelayered fabric are thinner than said panels of foam rubber material. 18.The garment of claim 1, wherein said waterproof, breathable layeredfabric comprises at least a first layer of synthetic knit fabric and atleast a second layer of a waterproof breathable membrane of expandedpolytetrafluoroethylene.
 19. The garment of claim 1, wherein saidwaterproof, breathable layered fabric comprises an inner layer ofsynthetic knit fabric, a middle layer of a waterproof breathablemembrane of thermoplastic polyurethane (TPU) film, and an outer layer ofsynthetic knit fabric.
 20. The garment of claim 6, wherein said innerand outer layers of the synthetic knit fabric are treated with adurable, water-repellant chemical.
 21. A method of manufacturing agarment suitable for water sports, comprising: affixing one or morepanels of foam rubber material having an inner and outer laminate ofsynthetic knit fabric and one or more layers of a waterproof, breathablelayered fabric wherein said waterproof breathable layered fabriccomprises at least a first layer of synthetic knit fabric and at least asecond layer of a waterproof breathable membrane to form a form-fittinggarment.
 22. The method of claim 8, further comprising the step oftreating said at least first layer of synthetic knit fabric with adurable, water-repellant chemical.
 23. The method of claim 8, furthercomprising the step of positioning said one or more layers of awaterproof, breathable layered fabric in areas of said garment wheregreater flexibility and movement is desired.
 24. The method of claim 8,further comprising the step of positioning said one or more layers of awaterproof, breathable layered fabric in areas of said garment wheregreater heat dissipation is desired.
 25. A garment suitable for watersports, comprising: at least one panel of waterproof, breathable layeredfabric wherein said layered fabric comprises at least a first layer ofsynthetic knit fabric and at least a second layer of a waterproofbreathable membrane.